Champion Pumps Cpg Users Manual

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Submersible Grinder Pump

CPG 2HP Grinder

Series

235651

Rev 11/12

Page 3

USER GUIDE

Congratulations on your purchase of a Champion Pump grinder pump system. With proper care and by following a

few simple guidelines, your grinder pump will give you many years of dependable service.

USE & CARE

The Champion grinder pump station is designed to handle routine, domestic sewage. Solid waste materials should

be thrown in the trash. While you station is capable of accepting and pumping a wide range of materials, regulatory

agencies advise that the following items should not be introduced into any sewer either directly or through a kitchen

waste disposal:

Glass; Metal; Diapers; Socks, rags or cloth; Plastic objects (e.g., toys, utensils, etc.) Sanitary napkins or tampons.

In addition you must never introduce into any sewer: Explosives; flammable material; lubricating oil and or grease;

strong chemicals; gasoline.

GENERAL INFORMATION

Your home wastewater disposal service is part of a low pressure sewer system. The key element in this system is

the grinder pump station. The basin collects all wastewater from the house. The solids in the sewage are then

ground to a small size suitable for pumping in the slurry. The grinder pump generates sufficient pressure to pump

this slurry from your home to the wastewater plant.

POWER FAILURE

This Pump cannot dispose of wastewater or provide an alarm signal without electrical power. If electrical power

service is interrupted, keep water usage to a minimum.

WARRANTY

Your pump is furnished with a warranty against defects in material or workmanship. A properly completed Start-

Up/Warranty Registration form must be on file at the Champion factory in order to activate your warranty. In

addition your pump must be installed in accordance with the installation instructions. If you have a claim under the

provisions of the warranty, contact your installer.

NOTE: ON CPG2022DSL MODELS, CAPACITOR KIT #28-0009-0000 MUST BE USED OR WARRANTY IS

VOID.

For future reference, record the following information:

Pump Model #____________________Pump Serial # ______________________

Installer_________________________Installer Phone #____________________

Date Installed____________________

RECEIVING / UNPACKING

Upon receiving the pump, it should be inspected for damage or shortages. If damage has occurred, file a claim

immediately with the company that delivered the pump. Unpack pump and record pump serial and model number

before installing. If the manual is removed from the packaging, do not lose or misplace.

SHORT TERM STORAGE

For best results, pumps can be retained in storage, as factory assembled, in a dry atmosphere with constant

temperatures for up to six (6) Months.

LONG TERM STORAGE

Any length of time exceeding six (6) months, but not more than twenty-four (24) months. The units should be

stored in a temperature controlled area, a roofed over walled enclosure that provides protection from the elements

(rain, snow, wind-blown dust, etc.), and whose temperature can be maintained between +40 deg. F and +120 deg.F.

If extended high humidity is expected to be a problem, all exposed parts should be inspected before storage and all

surfaces that have the paint scratched, damaged, or worn should be recoated with an air dry enamel paint. All

surfaces should then be sprayed with a rust-inhibiting oil. Pump should be stored in its original shipping container.

On initial start up, rotate shaft by hand to assure seal and motor rotate freely.

Page 4

USER GUIDE

INSTALLATION

The pump is provided with a leg kit in case a rail lift out system is not used. A minimum of 3” clearance must be maintained

between the pump and the basin bottom. If the feet are to be used, install the rubber threaded feet and lock with nut to ensure

3” clearance under pump for proper clearance of solids to enter pump inlet.

Assemble discharge piping or hose assembly to the pump. Discharge piping should be as short as possible. Both a check

valve and a shut off valve are required for each pump being used. The check valve is used to prevent backflow into the sump.

Excessive backflow can cause flooding and /or damage to the pump. The shut-off valve is used to stop system flow during

pump or check valve servicing. If pump is installed with a discharge hose rather than a moveable fitting assembly, make sure

the discharge pipe has a 1/8” hole approximately 5” from tend neatest volute and oriented towards the pump body.

ELECTRICAL CONNECTIONS

Breaker Recommendations: 25 AMP (208V-230V Single Phase) : 20AMP (208V-230V Three Phase) :15AMP (460V Three

Phase). The quick connect cord assembly mounted to the pump must not be modified in any way except for shortening to a

specific application. Any supply cables connections between the pump and the control panel must be made in accordance with

the National Electric Code or the Canadian Electric Code and all applicable state, province and local electric codes. It is

recommended that a junction box, be mounted outside the sump or be of at least Nema 4 (EEMAC-4) construction if located

within the wet well. The Ground Wire of pump is marked with an “E” for earth ground and is a Blue-Green Color. DO NOT

USE THE POWER OR CONTROL CABLES TO LIFT PUMP!

Check winding resistance of pump power cable before installation. The OHM readings should be approximately: CPG2022DS

Models: Black to White or across blades -1.3ohms; GPG2022DSL Models: Black to White – 1.3ohms; Red to White –

3.7ohms; Black to Red – 2.4ohms.

THREE PHASE GRINDER INSTALLATION: Check proper rotation. Improper motor rotation can result in poor pump

performance and pump failure. The power leads are the red, black and white wires. There should be approximately an equal

ohm resistance between these leads of approximately 1.6ohms for 230 Volt connection and 6.2 ohms for 460Volt. The blue-

green color lead is the ground wire. Once the leads are connected to the power terminals then you are ready to check the

rotation. Momentarily apply power to the pump with it laying on its side and impeller clear from obstruction. Observe

“kickback” as it should always be in counter-clockwise direction as viewed from top of the motor housing or opposite to

impeller rotation. If rotation is incorrect when power is supplied, then reverse two of the leads at the power terminal and try

again. This should correct the rotation. Once pump is in operation the amperage of each leg of the power connection should be

checked and recorded on the start up sheet. They should be close to the same value for each leg (within 5% of the average leg

to leg value). If they are not, try advancing the connections to balance the readings, but do not lose proper rotation.

If additional cord is required, consult a qualified electrician for proper wire size. On single phase models, the type of in-

winding overload protector used is referred to as an inherent overheating protector and operates on the combined effect of

temperature and current. This means that the overload protector will trip out and shut the pump off if the winding becomes too

hot, or the load current passing through them becomes too high. It will then automatically reset and start the pump up after the

motor cools to a safe temperature. All three phase models are not automatically protected. They do have on winding thermal

sensors accessed through the sensor cord (Black and Green wires) that need to be connected to an approved protection and or

alarm circuitry in the panel for winding thermal protection. Thermal protection shall not be used as a motor overload

device. A separate motor overload device must be provided in accordance with NEC codes. In the event of an overload,

the source of this condition should be determined and rectified immediately. DO NOT LET THE PUMP CONTINUE TO

RUN IF AN OVERLOAD CONDITION OCCURS. Full load amps are 15 amps for 230 Volt single phase; 17amps for 208

Volt single phase; 11.0, 9.0, & 4.5 amps for 208V, 230V, & 460V three phase models.

OPTIONAL MOISTURE SENSOR A detector is installed in the pump seal chamber which will detect any moisture present. It

is recommended that this detector (Black & White wires) be connected in series to an alarm device or the motor starter coil to

alert the operator that a moisture detect has occurred. In the event of a moisture detect, check the individual moisture sensor

probe leads for continuity and the junction box/control box for moisture content. This situation may induce a false signal in

the moisture detecting circuit. Normal resistance between leads is 33,000 OHMS indicating normal connection. When the

resistance drops well below 33,000 OHMS, then moisture is present and the pump seals should be serviced. If none of the

above tests prove conclusive, the pump(s) should be pulled and the source of the failure identified and repaired. IF A

MOISTURE DETECT HAS OCCURRED, SCHEDULE MAINTENANCE AS SOON AS POSSIBLE.

USER GUIDE

SERVICE

Lubrication: Anytime the pump is removed from operation, the cooling oil in the motor housing should be

checked visually for oil level and contamination.

Checking Oil: To check oil in the motor housing, set pump upright. Remove plug from motor housing.

With a flashlight, visually inspect the oil in the motor housing 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 the vertical position.

Testing Oil: Place pump on it’s side, remove plug from motor housing and drain oil into a clean, dry

container. 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 15KV. Breakdown), refill the motor housing. (See

Replacing Oil below) If oil is found to be dirty or contaminated, the pump must be carefully inspected for

leaks at the shaft seals, cord assemblies, O-rings, and plugs before refilling with oil. To locate the leak,

perform a pressure test. After leak is repaired, dispose of old oil properly, and refill with new oil.

Replacing Motor Housing Oil: Drain all oil from motor housing and dispose of properly per local and

environmental standards. Set unit upright and refill with new cooling oil. Fill to just above motor

(approximately 66oz) as an air space must remain in the top of the motor housing to compensate for oil

expansion. Apply pipe thread compound to threads on plug and insert and tighten into housing.

Replacing Seal Chamber Oil: Drain all oil from seal chamber and dispose of properly per local and

environmental standards. Set unit on its side, with plug upward, and refill with new oil. (approximately

13oz) Apply pipe thread compound to threads on plug and insert and tighten into housing.

WARNING! Do not overfill oil. Over filling of oil can create excessive and dangerous hydraulic pressure

which can destroy the pump and create a hazard. Overfilling oil voids warranty.

DIELECTRIC COOLING OIL : BP – Enerpar SE100: Conoco – Pale Paraffin 22; Mobile – D.T.E. Oil

Light; G&G Oil – Circulating 22; Imperial Oil – Voltesso-35; Shell Canada – Transformer-10; Texaco –

Diala-oil-AX; Woxo – Premium 100.

Pressure Test for pumps that have been disassembled.: If the pump has been disassembled, the oil should

be drained before a pressure test. Remove plug from motor housing. Apply pipe sealant to a pressure

gauge assembly and tighten into hole. Pressurize motor housing to 10 P.S.I. Use soap solution around the

sealed areas and inspect joints for “air bubbles”. If, after five minutes, the pressure is holding constant, and

no signs of leaks are observed, slowly bleed the pressure and remove the gauge assembly. Replace oil. If

the pressure does not hole, then the leak must be located and repaired.

CAUTION! Pressure builds up extremely fast. Too much pressure will damage seal.

Pressure Test for pumps that have not been disassembled.: The pressure test may be done with the oil at its

normal level. Remove plug from motor housing. Apply pipe sealant to a 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 the oil level, leaks will seep oil. If,

after five minutes, the pressure is holding constant, and no signs of leaks are observed, slowly bleed the

pressure and remove the gauge assembly. Replace oil. If the pressure does not hole, then the leak must be

located and repaired.

Seal Chamber Pressure Test: Set unit on its side with fill plug downward, remove plug and drain all oil

from seal chamber. Apply pipe sealant to pressure gauge assembly and tighten into hole in seal plate.

Pressurize seal chamber to 10 P.S.I. and check for leaks as outlined above.

Page 5

NOTE: CPG2022DSL MODELS MUST HAVE

CAPACITOR KIT # 28-0009-0000

OR WARRANTY IS VOID

NOTE: All 3 Phase Models Check Proper Rotation - Cause Low Performance, Noise, and Vibration

Specifications

Page 9

DISCHARGE………………………..1-1/4" NPT. Vertical

SOLIDS HANDLING……………………………………3”

LIQUID TEMP……..……150 DEG. F. INTERMITTENT

MOTOR HOUSING…………………………….Cast Iron

VOLUTE…………………………………………Cast Iron

SEAL PLATE……………………………………Cast Iron

IMPELLER……………………………………… Cast Iron

SHAFT……………………………….416 Stainless Steel

MOTOR……. ( 1 PHASE) 3450 RPM. 60 Hz NEMA L

Includes Overload Protection In The Motor

Oil Filled, Class F Insulation

Capacitor Start / Capacitor Run

CPG-DSL Models – Capacitors & Protection

In Control Panel

(3 PHASE) 3450 RPM 60Hz NEMA B

Requires Overload Protection In Panel

OPTIONAL SEAL FAILURE……20’ Length Standard

UL / CSA (SJTW) 16/3 (.330OD)

WEIGHT………………….85 lbs Manual (Double Seal)

……………………75 lbs Manual

(

Sin

g

le Seal

)

SHAFT SEAL - (SINGLE SEAL)

Silicon Carbide-Silicon Carbide

Buna-N- Elastomer

300 Series Stainless Steel - Hardware

SHAFT SEAL - (DOUBLE SEAL)

Tandem Double Mechanical

Upper / Carbon-Ceramic

Lower/ Silicon Carbide-Silicon Carbide

Buna-N- Elastomer

300 Series Stainless Steel - Hardware

BEARING (UPPER & LOWER

Single Row, Ball. Oil Lubricated

HARDWARE…………………316 Series Stainless Steel

O-RINGS……………………………………………..Buna-N

CORD…............................................20' Length Standard

UL / CSA (SJOW) 14ga (.375OD)

UL / CSA (SO) 14ga (.60 OD) 460Volt

CORD ENTRY………….Quick Disconnect Pin Terminals

Page 11

Start-Up Report / Warranty Registration

Please fill out the following questions as completely and accurate as possible. Please

mail to Champion Pump Company, Inc. – P. O. Box 528 – Ashland, OH 44805.

REPORTS THAT ARE NOT RETURNED CAN DELAY OR VOID WARRANTY.

Pump Owner’s

Name:__________________________________________________________________

Address:________________________________________________________________

Location of installation:____________________________________________________

Phone:__________________________________________________________________

Purchased from:__________________________________________________________

Pump Model_______________Serial #__________________Date Code:_____________

NOTE: CPG2022DSL MODELS MUST HAVE CAPACITOR KIT #28-0009-0000 OR

WARRANTY IS VOID.

Date Installed:____________________________________________________________

Does impeller turn freely by hand? YES____________NO___________________

Condition of cord jacket? Good________Fair________________Poor_____________

Was equipment stored?___________How long?_________________________________

Liquid being pumped______________________________________________________

Debris in bottom of station?________Was debris removed in your presence?__________

Discharge pipe size?___________ Length of pipe?_________Static lift?_____________

Does station appear to operate at the proper rate?_______Pump down time?___________

Voltage At Wiring Terminal L1-L2___________L2-L3___________L1-L3___________

Run Amps L1_______________L2_______________L3_______________

3 Phase Models – Check Proper Rotation? Yes / NO

Difficulties during start up: _________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

I certify this report to be accurate (start up person)_______________________________

Employed by___________________________________ Date: ____________________