EP45 - Water pump Ashland - Free user manual and instructions

USER MANUAL EP45 Ashland

• Thank you for purchasing this pump. Take the time to read the instructions carefully before using this product. We strongly recommend that you keep this instruction manual in a safe place for future reference.

• Please refer to our website and the Products Center for additional installation and operation instructions and replacement parts information. OPERATION, PERFORMANCE, SPECIFICATIONS and PARTS MANUAL EP40 & EP45 4/10 & 1/2 HP Effluent Pumps Effluent Pump Models EP40 & EP45 Series “Danger” indicates an imminent hazardous situation which, if not avoided, WILL result in death or serious injury. “Caution” indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury. WARNING CAUTION DANGER “Warning” indicates an imminent hazardous situation which, if not avoided, MAY result in death or serious injury.

DANGER Before installation, read the following instructions care- fully. Failure to follow instruction and safety information could cause serious bodily injury, death and/or property damage. Each Ashland Pump is individually factory tested to ensure proper performance. Closely following these instructions will eliminate potential operating problems assuring years of trouble-free service. Most accidents can be avoided by using common sense. IMPORTANT - Ashland Pump is not responsible for losses, injury or death resulting from failure to observe these safety precautions, misuse, abuse or misapplica- tion 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 materials. All applicable laws and regulations shall apply. Bronze/brass fitted pumps may contain lead levels higher than con- sidered 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 accord- ance with the National Electric Code and all applicable state and local codes. Requirements may vary depend- ing on usage and location. Installation and servicing is to be conducted by qualified personnel only. Rotating machinery, amputation or severe lacerations can result. Keep clear of suction and discharge openings. DO NOT insert fingers into 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 ser- vicing. Hazardous Voltage can shock, burn or cause death. This pump is not intended for use in swimming pools or water installations where human contact with pumped fluid is possible. Risk of electrical shock. To reduce risk of electrical shock, always disconnect pump from source before handling. Lock out power & tag. Effluent Pumps Model: EP40 & EP45 Series General Safety Information WARNING Do Not use these pumps in water over 145°F. Do not exceed manu- factures recommended maximum performance, as this could cause the motor to overheat. WARNING WARNING WARNING WARNING DANGER DANGER DANGER These pumps are NOT to be installed in locations classified as hazardous in accordance with the National Electric Code, ANSI/NFPA 70. WARNING Effluent 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 ba- sin after it has been used. WARNING Do not introduce into any sewer, either directly, or through a kitchen waste disposal unit or toilet: Seafood Shells, Aquarium Gravel, Cat Litter, Plastic Objects, Sanitary Napkins or Tampons, Diapers, Rags, Disposable Wipes or Cloth, Medications, Flammable Material, Oil or Grease, Strong Chemicals, Gasoline. DANGER DANGER Do not lift, carry or hang pump by the electrical cables. Damage to the electrical cables can cause shock, burns or death. Never handle connected power cords with wet hands. Use appropriate lifting device. DANGER Failure to permanently ground the pump, motor and controls before connecting to power can cause shock, burns or death. DANGER Make sure lifting handles are securely fastened each time before lifting. CAUTION

• Operation against a closed discharge valve will cause premature bearing and seal failure on any pump.

• Any wiring of pumps should be performed by a qualified electrician.

• Cable should be protected at all times to avoid punctures, cuts, bruises, and abrasions-inspect frequently.

• Never handle connected power cords with wet hands.

• Never let cords or plugs lie in water outside the sump pit.

• These pumps are offered in a three phase and single phase wiring configuration. Voltages will vary according to the application and can be seen in the tables in this manual.3

Effluent Pumps Model: EP40 & EP45 Series Specifications IMPORTANT Prior to installation, record Model Number, MFG Date, Amps, Voltage, Phase and HP, from pump nameplate for future reference. Also record the voltage and current readings at startup: Model Number: MFG Date: HP: SN: 1 Phase Models Amps: Volts: SPECIFICATIONS Overall Size Pump Material (inches) Motor Model HP Volt Ph Amps L W H Volute Housing Impeller Shaft EP40M1-20 4/10 115 1 9.0 9.8 7 13.7 Cast Iron Cast Iron Cast Iron SS EP40M2-20 4/10 230 1 4.5 9.8 7 13.7 Cast Iron Cast Iron Cast Iron SS EP45M1-20 1/2 115 1 11.0 9.8 7 13.7 Cast Iron Cast Iron Cast Iron SS EP45M2-20 1/2 230 1 5.5 9.8 7 13.7 Cast Iron Cast Iron Cast Iron SS Note: All dimensions have a tolerance of + 1/8” Description: To pump domestic, commercial and light industrial sewage Physical Data:

ACCEPTABLE PH RANGE 6-8

SPECIFICATIONS5 Effluent Pumps Model: EP40 & EP45 Series Receiving and Installation Receiving Inspection 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. 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. IMPORTANT! A clearance under the pump for entrance of sewage solids must be a minimum of 2 inches to a maximum of 3.5 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 motor (see fig. 1), unless very briefly. Installation The sump or basin shall be sealed and vented in accor- dance with local plumbing codes. This pump is designed to pump domestic wastewater, nonexplosive and non- corrosive liquids and shall NOT be installed in locations classified as hazardous in accordance with the National Electrical Code (NEC) ANSI/ NFPA 70 or Cana- dian 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.

Discharge Piping Install discharge piping or hose assembly to the pump. Discharge piping should be as short as possible and sized no smaller than the pump discharge. Do not reduce the dis- charge pipe size below that which is provided on the pump. Both a check valve and a shut-off valve are recommended for each pump. The check valve is used to prevent backflow into the sump. The shut-off valve is used to manually stop system flow during pump servicing. Be sure the discharge pipe has a 1/8” diameter hole approx. 5” from end nearest volute and oriented towards the pump body. Control Panel Single phase series effluent pumps DO NOT require a con- trol panel, but do require a level control with a piggy back plug, see “Piggy-back Plug, figure 2” below.

WARNING Motor: Each motor is provided with heat sensor thermo- stats attached directly to the motor windings. The thermostats open if the motor windings see excessive heat and, in turn, open the motor contactor in the control panel when used, breaking the power to the pump. When the motor is stopped due to an overheated condition, it will not start until the motor has cooled. FIGURE 1 14” Minimum Submergance Pre-operation

CHECK VOLTAGE AND PHASE

Before operating pump, check to make sure that voltage and phase information stamped on the pump’s identifica- tion plate matches the available power.

Before putting pump into service for the first time, the motor rotation must be checked. Improper motor rota- tion can result in poor pump performance and can damage the motor and/or pump. IDENTIFICATION PLATE Note the numbers on the pumps identification plate and record in this manual for future reference. Electrical Connections Turn circuit breaker off before plugging or unplugging the switch and/or pump. Always rely upon a Certified Electrician for installation. Piggy-Back Plug Plug the level control plug into a 115V receptacle, then plug the pump into the piggy-back plug (See Figure 2). It is recommended that this circuit have a 15 AMP breaker. One cycle of operation should be observed, so that any potential problems can be corrected. FIGURE 2 Automatic Manual6 Effluent Pumps Model: EP40 & EP45 Series Receiving and Installation It is recommended that the level control float should be set to insure that the liquid in the sump never drops below the top of the motor housing. 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 “Off ” mode. Minimum tether length is 3.50”. By adjusting the cord tether the control level can be changed. DO NOT USE THE POWER CABLE TO LIFT PUMP. Pump-Down Test - Be sure pump has been plugged in, lowered into the basin or sump, check the system by filling 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. Thermal Protection The normally closed (N/C) over temperature sensor is embedded in the motor windings and will detect exces- sive 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. In the event of an over temperature, the source of this condi- tion should be determined and repaired immediately. Ther- mal protection shall not be used as a motor overload device. Maintenance Minimal maintenance is required. Perform the following checks when pump is removed from operation or when pump performance deteriorates: a). Inspect motor chambers 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 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 from housing. With a flashlight, visually inspect the oil in the 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 vertical position. Oil Testing

• Drain oil into a clean, dry container by placing pump on it’s side. Remove pipe plug, from housing.

• 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), refill 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, o- ring and pipe plug, before refilling with oil. To locate the leak, perform the following pressure tests. After leak is repaired, dispose of old oil properly, and refill with new oil. Pressure builds up extremely fast, increase pressure by “TAPPING” air nozzle. Too much pressure will damage seal. DO NOT exceed 10 P.S.I. Motor Housing Pressure Test: If oil has been drained, fill to normal level before perform- ing pressure test. Remove pipe plug from motor housing. Apply pipe sealant to pressure gauge assembly and tight- en 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, leaks will seep oil. If, after five 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. Leak must be located and repaired if pressure does not hold. Oil Replacement Motor Housing Remove pipe plug from motor housing. Drain all oil (if not already done so) from motor housing and dispose of properly per Local Code. Set pump upright and refill with new cooling oil, see “Cooling Oil” chart. Fill to just above motor (.9L) as an air space must remain in the top of the motor housing to compen- sate for oil expansion. Apply pipe thread compound to threads of pipe plug then assemble to motor housing. Check that o-ring is in place and does not need to be replaced. Reassemble cord cap to motor housing. DO NOT overfill oil. Overfilling of housing with oil can create excessive and dangerous hydraulic pressure which can destroy the pump and create a hazard. Overfilling oil voids warranty. Cooling Oil Recommended Supplier/Grade BP Enerpar SE100 Conoco Pale Paraffin 22 Mobile D.T.E. Oil Light Shell Canada Transformer-10 Texaco Diala-Oil-AX Before any service work is done, disconnect and lock out electrical power to pump. WARNING7 Effluent Pumps Model: EP40 & EP45 Series Installation and Service Volute - Remove socket head cap screws from volute. Impeller - Remove impeller by turning counter-clockwise; careful application of heat may be necessary. Do Not store pump without impeller in place. Seal- Handle seal parts with care. Remove rotating mem- ber from shaft. Remove pressed-in spring component from seal plate. Examine all seal parts. Inspect contact faces for signs of uneven wear tracks on stationary face, chips and scratches on either seal face. DO NOT inter- change seal components, replace the entire shaft seal if necessary. Seal Plate - Remove cap screws from seal plate. Remove seal plate and o-ring. Bearings - Using a bearing puller or arbor press remove bearing from shaft. Remove upper motor bearing from shaft with a bearing puller. IMPORTANT! - All parts must be clean before reassembly. Handle seal parts with extreme care. DO NOT damage lapped surfaces. REASSEMBLY Bearing - Be careful not to damage the rotor shaft when replacing bearing. 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. In the same manner replace lower bearing (49) onto rotor shaft. Seal Plate - Lubricate and set o-ring in bottom of seal plate. Place seal plate over shaft, being sure o-ring is not twisted and in the groove. Place four capscrews through holes in motor housing and into seal plate and torque to

Outer Seal - Clean and oil stationary seal cavity in seal plate. Slide seal guide tool over motor shaft. Lightly oil (Do not use grease) outer surface of seal’s stationary member. Press stationary firmly into seal plate using a seal pusher tool. Be sure the stationary member is in straight. Noth- ing but the seal tool is to come in contact with seal face.

IMPORTANT ! Do not hammer on the seal pusher. It will damage the seal face. With lapped surface of rotating member facing inward toward stationary, slide rotating member and onto shaft, until lapped faces of stationary and rotating seal are together. Impeller - Place impeller on motor shaft by turning clock- wise. Blue thread locking compound is recommended. Volute - Place volute on seal plate. Place socket head cap screws through volute and into seal plate Then torque evenly to 11 ft/lbs.8 Effluent Pumps Model: EP40 & EP45 Series Installation and Service Starting Pump After Installing in Basin Before lowering pump into basin, connect power lines and start motor. Impeller should turn counterclockwise when looking at impeller. Service and Repair Important: Pump should be thoroughly cleaned of trash and deposits before starting disassembly operations (pages 6-8). Disconnect all power and control wires to motor at control panel before starting disassembly operation. Never rely on opening circuit breaker only. Operating pump builds up heat and pressure; allow time for pump to cool to room temperature

Installing Pump in BASIN Install pump in properly vented basin according to local codes and regulations. PVC pipe along with plastic check valve and shut-off valve are recommended. Drill a 1/8” hole in the discharge pipe below the check valve. Install check valve 12” above pump discharge. See Figure 3 CAUTION FIGURE 3 WARNING

Entry pipeDischarge pipe Vent Shut-off valveCheck valveUnionTo control panelAir bleed hole9 ELECTRICAL PRECAUTIONS Before servicing a pump, always shut off the main power breaker and then unplug the pump. Make sure you are not standing in water and are wearing insulated protective sole shoes, under flooded conditions. Contact your local electric company or a qualified licensed electrician for disconnecting electrical service prior to pump removal Effluent Pumps Model: EP40 & EP45 Series Trouble Shooting PROBLEMS

POSSIBLE CAUSES/SOLUTIONS

• Line circuit breaker is off, or fuse is blown or loose

• Water level in sump has not reached turn-on level as indicated in installation drawing.

• Pump cord is not making contact in receptacle.

• Float is stuck. It should operate freely in basin.

• If all of the above are OK, then the motor could be malfunctioning.

• Check if valve is installed backwards. Arrow on valve should point direction of flow

• Discharge shut-off valve (if used) may be closed.

• Impeller or volute openings are fully or partially clogged. Remove pump and clean.

• Pump is air-locked. Start and stop several times by plugging and unplugging cord. Check for clogged vent hole in pump case.

• Inlet holes in pump base are clogged. Remove pump and clean the openings.

• Vertical pumping distance is too high. Reduce distance or change the discharge fittings of the pump.

• Float is stuck in up position. Be sure float operates freely in basin.

• Pump is air-locked. Start and stop several times by plugging in and unplugging cord. Check for clogged vent hole in pump case.

• Vertical pumping distance is too high. Reduce distance or change the discharge fitting of the pump. Inlet holes in pump base are clogged. Remove pump and clean the strainer and openings.

• Impeller or volute openings are fully or partially clogged. Remove pump and clean.

• Pump impeller is partially clogged with tar or paint, causing motor to run slow and overload. Remove pump and clean.

• Pump impeller is partially clogged causing motor to run slow and overload. Remove pump and clean.

• Motor stator may be defective.

• Fuse size or circuit breaker may be too small. (must be 15 amps).

• Impeller or volute opening are fully or partially clogged. Remove pump and clean .

• Inlet holes in pump base are clogged. Remove pump and clean the openings.

• Pump impeller is partially clogged causing motor to run slow and overload. Remove pump and clean.

• Motor stator may be defective.

• Impeller or volute openings are fully or partially clogged. Remove pump and clean. Also clean the strainer if one is installed.Effluent Pumps Model: EP40 & EP45 Series Parts

17 PLUG 091EP4025 1 1 18 HANDLE 091EP4026 1 1 19 SCREW 091EP4027 2 212 1899 Cottage Street, Ashland, Ohio 44805 Telephone: [phone] • Fax: [phone] ashlandpump.com P U M P Honest, Professional, Dependable AP-0162/EP40/45 OM-rev07/2020 For a period of time no greater than three (3) years after the original purchase of the subject product, and subject to the conditions of this Limited Warranty, Ashland Pump will repair or replace for the original purchaser only, any portion of your new Ashland Pump product that proves to contain defective materials or defective workmanship, provided the product is properly installed, serviced and operated under normal conditions and according to the manufacturer’s instructions. Ashland Pump disclaims all liability, including liability under this Limited Warranty, for improper installation, application or use of its products. Ashland Pump shall have and possess the sole discretion to determine whether to repair or replace defective equipment, parts or components with a new or remanufactured part. Any item to be replaced under this Warranty must be returned to Ashland Pump, or such other place as Ashland Pump may designate, freight prepaid. In the absence of suitable proof of purchase date, the eective date of this warranty will be based upon the date of manufacture as evidenced by the serial number of the product. There is no other express or implied warranty covering your Ashland Pump product. Without limiting the foregoing, Ashland Pump specically disclaims the implied warranties of merchantability and tness for a particular purpose. No warranties or representations at any time made by any representative of Ashland Pump shall vary or expand the provisions of this written Limited Warranty. This Limited Warranty contains the purchaser’s exclusive remedy for any alleged defect in the product. To the greatest extent permissible by applicable law, Ashland Pump shall not be liable or responsible for consequential, incidental or special damages resulting from or related in any manner to any Ashland Pump product or parts. Personal injury and/or property damage may result from improper installation, application or use of your Ashland Pump product. Ashland Pump shall not be liable for any loss, damage, or expenses resulting from the installation or use of its products other than as expressly set forth in this Limited Warranty. Ashland Pump shall in no event be responsible or liable for the cost of eld labor or other charges incurred by any purchaser or user in removing and/or reaxing any Ashland Pump product, part or com- ponent or any temporary pumping or other equipment. 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. Effluent Pumps Model: EP40 & EP45 Series Warranty13 MANUAL DE OPERACIÓN, DESEMPEÑO, ESPECIFÍCACIONES Y

CAUSAS POSIBLES/SOLUCIONES

CAUSES/SOLUTIONS POSSIBLES