Gatorgrinder Typical Installation Instructions

Gatorgrinder Typical Installation Instructions
Gatorgrinder
Typical
Installation
Instructions
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The Gatorgrinder is a wellengineered system designed
to provide low pressure sewer
service to individual residences
or buildings. Proper installation
of this equipment will ensure
years of trouble-free service.
PRODUCT DESCRIPTION
The Gatorgrinder station
consists of a grinder pump,
tank and pump alarm panel.
The tank is a fiberglass basin
complete with a gasketsealed, fiberglass lid. Sewage
enters the Gatorgrinder tank
through the 4” (standard) inlet
pipe where it is ground into
fine particles by the grinder
pump. The in-line pumping
mechanism discharges the
ground sewage to a force
main, gravity main or a remote
treatment site. The pump is
a semi-positive displacement
type capable of developing
discharge pressures up to
80 psig. Ample tank storage
capacity in conjunction with
integral level sensing controls
provides for economic, ondemand, operation of the
grinder pump.
ITEMS REQUIRED FOR
INSTALLATION
Prior to beginning installation
of the Gatorgrinder station,
a thorough review of these
installation instructions is
recommended. This will
likely eliminate problems
with inconvenient piping
and cable locations or due
to unavailable materials or
equipment. In addition to the
components furnished with
each Gatorgrinder station, the
following items will be needed
to support installation:
• Supply voltage in
accordance with the voltage
specified on the Gatorgrinder
nameplate.
• Bedding material (Section
2)
• Concrete ballast (Section 3)
• 4” inlet pipe (from residence
or building sewer) (Section 5)
• 1-1/4” discharge pipe to
force or gravity main (Section
6)
• Compactible backfill
material (Section 9)
The following tools:
• 5” diameter hole saw
• 1-1/16” diameter hole saw
• Pipe thread sealant
(suitable for PVC)
• Pipe wrenches
• Water pump pliers
• Electric drill, 1/2” chuck
• Common hand tools
INSTALLATION STEPS
The following instructions
will provide the necessary
information to properly install
the Gatorgrinder system.
All applicable OSHA
procedures must be followed
during installation of this
equipment.
1. Station Unpacking
(Figure 1)
The Gatorgrinder alarm
panel, grinder pump and
tank are shipped to the job
site separately. Inspect the
tank (1) and ensure that it
sustained no damage during
shipment. Proper handling of
the fiberglass tank will ensure
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reliable performance. Do not
drop the fiberglass tank or roll it
on its side. Only a non-marring
sling should be used to lift the
fiberglass tank.
Ensure that all lifting
equipment is rated for the
load being lifted. Verify that
the discharge fitting (4) is
installed on the tank. Remove
the fiberglass tank lid (2) and
verify that the lid gasket (3) is
installed.
The balance of the factory
provided components were
delivered with the grinder
pump unit. Inspect the
shipping cartons for signs of
any damage sustained during
shipment.
If damage is suspected
on any of the Gatorgrinder
components, do not proceed
with installation. Notify your
distributor of any damage
discovered.
Open the shipping cartons
and verify that the grinder
pump (5), pump stand (6),
discharge piping kit (7), supply
cable (8), cable grip (9), inlet
grommet (10) and alarm panel
(11) are enclosed. Notify your
E/One distributor about any
missing components.
2. Site Excavation
Excavate a hole of
sufficient depth and width
to accommodate the tank,
underground piping and
required backfill material as
well as providing adequate
working space for plumbing
and electrical connections.
The base of the excavated
hole should be level and
prepared with proper bedding
material, such as gravel,
in accordance with the site
engineer’s requirements. The
depth of the excavation must
be sufficient to accommodate
the bedding material and
tank burial to approximately
1” below the upper flange
surface. The size, shape and
shoring requirements of the
FIGURE 2 - TANK INSTALLATION
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excavation will be based on
the soil conditions and should
be in accordance with the site
engineer’s recommendation
and safety requirements.
3. Tank Installation
(Figure 2)
Improper handling of the
fiberglass tank may result in
damage and, ultimately, failure
of the station. Care should
be taken during lifting and
placement to prevent impacting
or otherwise damaging the
tank. A non-marring sling
should be used when lifting the
tank by the fiberglass surfaces.
Ensure that lifting sling is rated
for the load being lifted. Lifting
chains or cables should never
be placed in direct contact with
the fiberglass tank surfaces.
Place the tank on the level
bed of fill material in the
excavated hole. Orient the
installed discharge fitting, as
required, to align it with the
existing or proposed discharge
piping path. Determine and
mark the 4” DWV inlet pipe
location on the fiberglass tank
wall. The inlet pipe location
corresponds with the actual or
projected point where the 4”
building sewer line intersects
the tank wall. The center
of the inlet pipe must be a
minimum of 30 inches from
bottom of the tank. The slope
of the inlet pipe (per national
and local code requirements)
must be accounted for when
determining the inlet location.
The supply cable path and
cord grip location should be
considered when selecting the
inlet location (Section 8 and
Figure 4). If the site conditions
require concrete tank ballast
to prevent flotation, ensure
that the volume of concrete
used complies with the site
engineer’s recommendation.
Concrete ballast, if required,
should be cast in place around
the tank in the excavation. Do
not pour the concrete ballast
above the marked inlet pipe
location. If the ballast must
be poured above this level,
proceed with installation of the
inlet piping (Section 5) before
pouring the concrete. The inlet
pipe must be sleeved with an
8” tube prior to pouring. The
tank should be filled with water,
to a level above the specified
ballast height to prevent
shifting during the concrete
pour.
Alternatively, precast
concrete, around the tank
bottom, may be used for
ballast (Figure 2). Do not pour
ballast above the intended inlet
location. If this ballast method
is used, lifting hooks must be
anchored in the concrete to
support subsequent handling
of the tank. The lifting hooks
must be adequate to support
the combined weight of the
tank and concrete ballast, and
should be sized and installed
in accordance with the site
engineer’s recommendation.
FIGURE 3 - INLET INSTALLATION
Place the ballasted tank in
the excavated hole using the
lifting hooks. Do not lift the
tank by any of the fiberglass
surfaces if precast ballast is
utilized.
4. Vent Installation
The Gatorgrinder station is
supplied with a 2” mushroom
vent, to be installed in the
station cover.
Locate the 3” hole in the
station cover. A vent hole may
be added to a station cover in
the field using a 3” diameter
hole saw. Consult the factory
before installing a vent hole
in an existing station cover.
Install the rubber grommet
in the hole in the station. The
flange on the grommet should
sit flush with the station cover.
Apply soap to the end of the
nipple on the vent assembly.
Align the nipple on the vent
assembly with the grommet in
the station cover and press the
vent assembly down into the
grommet until the vent housing
bottoms on the grommet.
5. Inlet Installation
(Figure 3)
The type, size and venting
requirements of the inlet pipe
must be in accordance with all
national and local plumbing
codes. The Gatorgrinder is a
sewage handling pump and
requires ventilation for proper
and safe operation.
The Gatorgrinder is supplied
with a standard grommet to
accept a 4” DWV (4.5” outside
diameter) sewer inlet pipe. The
grommet is self-sealing and
does not require the use of
additional sealant or adhesives.
Other grommet sizes are
available upon request. Verify
that the grommet supplied
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with the Gatorgrinder will
accommodate the selected
inlet piping.
Using a 5” hole saw, drill
through the fiberglass tank wall
at the marked inlet location.
Install the supplied inlet
grommet in the 5” hole.
Place a mark on the inlet
pipe 3 1/2” in from the end that
will enter the fiberglass tank.
A bevel should be ground or
filed on the pipe end to aid
in installation through the
grommet. Clean the grommet
and pipe surfaces to remove
any debris. Apply a film of
pipe soap or dish soap to the
outside surface of the inlet
pipe end and the inside of the
grommet. Insert the pipe end
into the grommet and push the
inlet pipe into the fiberglass
tank until the 3 1/2” mark lines
up with the grommet outside
edge.
Inspect the grommet flange
on the outside of the tank. The
flange should be flush against
the tank wall and completely
visible when the pipe and
grommet are installed properly.
6. Tank Discharge Piping
Connection
Connect the tank discharge
piping to the threaded tank
fitting. The 1 1/4” NPT female
thread on the discharge fitting
will accommodate a variety
of pipe materials and fittings.
The discharge fitting is made
of reinforced Nylon and the
threads may be damaged if
overtightened. Use a suitable
threaded adapter and thread
sealant to connect the
discharge piping to the tank
fitting. Typically, 1/2 to 1 1/2
turns beyond hand tight will
produce a leak proof seal.
Discharge piping must be
selected in accordance with
local and national plumbing
codes. If allowable, the use of 1
1/4, Schedule 40, Type 1, PVC
pipe or SDR 11 polyethylene
pipe is recommended. If
polyethylene discharge piping
is used, compression type
fittings that provide a smooth
inner passage should be
utilized.
E/One requires that an E/One
NOTE: Conduit may
be required for the full
length of the E/One
supply cable. Refer to
your local electrical
code.
FIGURE 4 - SUPPLY CABLE INSTALLATION
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Uni-Lateral assembly (E/One
part number NB0184PXX
or NC0193GXX) or E/One
Redundant Check Valve
(E/One part number
PC0051GXX) be installed in
the pipe lateral outside the
home between the pump
discharge and the street main
on all installations. Never use
a ball-type valve as a check
valve. E/One recommends
the valve be installed as close
to the public right-of-way as
possible. Check local codes for
applicable requirements.
7. Alarm Panel Mounting
Before proceeding, verify that
the supply voltage is the same
as the motor voltage shown on
the grinder pump nameplate.
Determine the location of the
Gatorgrinder alarm panel.
The alarm panel may be
mounted on a pole or directly
on an outdoor wall surface.
The mounting location selected
must be visible from the
Gatorgrinder station location
and provide general visibility to
the occupants of the building.
To mount the alarm panel,
remove the panel front cover
and secure to the wall or
pole using standard #10 or
#12 screws through the two
mounting holes located on the
back panel.
8. Supply Cable Installation
(Figures 4 & 5)
A 32’ supply cable and
cord grip are provided with
the Gatorgrinder station for
electrical connection between
the station and the alarm panel.
All electrical wiring must be in
accordance with local codes.
A dedicated 30 amp breaker
is required before all simplex
alarm panels.
The supply cable is rated
under the National Electric
Code (NEC) for direct burial
as long as a minimum of 24”
of ground cover is maintained.
Those portions of the cable
with less than 24” of cover
must be housed in a suitable
protective conduit.
The supply cable terminates
in a convenient, electrical
quick-disconnect (EQD) plug
to support future servicing of
the grinder pump. The supply
cable cord grip provides a leak
tight seal around the power
cable as it enters the tank
and will prevent movement
of the supply cable during
burial and subsequent ground
settlement. The cord grip
should be installed in a position
on the tank that will provide
convenient, direct routing of
the supply cable to the alarm
panel. The supply cable cord
grip should be installed 25”
below the top of the tank (see
Figure 4).
Exception: On 48” tall
tanks the cord grip should
penetrate the tank 18”
below the top of the tank;
the portion of the cable with
less then 24” of soil cover
shall be installed in suitable
protective conduit.
Locate and mark the
location of the cord grip on the
fiberglass tank wall. Using a 1 1/16” hole saw, drill through
the tank wall at this location.
Install the cord grip and O-ring
seal as shown. Tighten the
cord grip locknut until snug.
Loosen the cord nut and
slide the supply cable free end
through the cord grip (Figure
4). Continue to slide the entire
cable length through the cord
grip until the metal cable stop
rests against the cord grip face.
Tighten the cord nut until snug.
Failure to tighten the cord
nut will result in groundwater
entering the station.
Use care when installing
and burying the supply cable.
If the cable is cut or otherwise
damaged it may result in a
pump malfunction. Run the
supply cable underground,
ensuring 24”, minimum, of soil
coverage, to the alarm panel
location. Leave a 6” to 12”
loop of supply cable near the
station and the alarm panel to
accommodate settlement of the
soil. A protective conduit must
be utilized where 24” of soil
cover cannot be maintained
(Figure 5).
9. Tank Backfill
Proper backfill is essential
to the long-term reliability of
the Gatorgrinder station. The
choice of backfill material is
dependent upon the local soil
and groundwater conditions
and must be in accordance
with the site engineer’s
recommendation. Heavy, noncompactible clays and silts are
not acceptable backfill for the
Gatorgrinder tank or any other
underground structure such as
the inlet or discharge piping.
Backfill should be placed and
compacted in 12” lifts. Special
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and adequate strain relief
used on cable and/or conduit
entry points. The appropriate
wiring connections for the
Gatorgrinder are shown in
Figures 7. A dedicated 30 amp
breaker is required before all
simplex alarm panels.
FIGURE 6 - PUMP STAND INSTALLATION
care should be taken when
placing backfill around inlet
and discharge piping to ensure
support and compaction.
Do not strike the inlet pipe,
discharge pipe or electrical
connection with the compaction
equipment during backfill.
The finished grade should
be 1” below the upper flange
on the fiberglass tank. The
finished grade should be
sloped down from the station
to prevent water from pooling
around the tank.
10. Grinder Pump
Stand Assembly
Temporarily rest the grinder
pump on its side. Using a block
of wood or similar object, prop
up the lower pump end to
allow installation of the pump
stand. Align the two legs of
each pump stand half with two
of the holes in the pump lower
end. Push the stand legs into
the pump lower end. Using a
mallet, ensure that the stand
legs bottom into the mounting
holes. Repeat for the other
stand half. Turn the pump
upright on the installed stand.
11. Grinder Pump Installation
Lower the pump into the
tank. Position the pump so
the pump’s discharge is on
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the opposite side of the pump
relative to the discharge in
the tank. Position the pump
in the center of the tank.
Rotate to coil the discharge
hose and slide the adapter on
the discharge hose into the
receiver in the tank wall. Push
the white slider down to open
the discharge valve.
Hang power cable, breather
tubing with Equalizer, and
lifting rope to prevent them
from laying in sewage. Keep
between 18 inches and 24
inches of power supply cable in
tank. The Equalizer should be
hung as high as possible in the
tank.
12. Electrical Connections
The Gatorgrinder alarm panel
contains a circuit breaker pair
to protect the pump motor and
a separate circuit breaker to
control the alarm circuit. The
station supply cable and power
supply cable (from the building
service) must be run into
the panel and appropriately
connected. All panel wiring
should be completed by a
qualified electrician and be
in compliance with national
and local electrical codes.
Conduit should be provided,
where required by code,
13. Start-Up Test Procedure
When the system is
completely installed, the station
should be checked to ensure
proper installation and reliable
performance.
SYSTEM INSPECTION
Perform the following visual
inspections:
• Proper burial depth —
the tank should have been
buried to a level 1” below the
fiberglass cover flange.
• Proper grading — the
surrounding soil should be
graded down, away from the
station.
• Station supply cable —
the station supply cable must
not be exposed outside of
the station. Suitable conduit
must be used where proper
burial depth (24”) cannot be
maintained.
• Alarm panel — ensure that
the alarm panel is properly
mounted and free of any
damage. Verify that the alarm
panel has been wired properly
in accordance with the wiring
instructions in this manual.
ELECTRICAL TESTS
The following electrical tests
are recommended prior to
operating the grinder pump
station. These tests require the
use of appropriate electrical
test equipment and should
only be performed by qualified
personnel trained in the safe
operation of this equipment and
electrical system servicing.
1. Ensure that the electrical
power supplying the alarm
panel is “OFF.”
2. Ensure that the grinder
pump (double) and alarm
(single) circuit breakers in the
alarm panel are in the “OFF”
position.
3. Using a test (ohm) meter,
set at a 2 meg ohm setting,
measure the resistance
between the colored wire pairs
shown in Table 1. Resistance
readings are to be taken
in the alarm panel on the
colored leads supplying the
pump station (supply cable).
Resistance readings other
than those shown in Table 1
TABLE 1
COLOR 1 COLOR 2
GRN/YEL RED
GRN/YEL BROWN
GRN/YEL BLACK
NORMAL
READING
:
:
:
: = Infinity or open circuit
may indicate a problem with
either the supply cable or the
grinder pump. If the measured
readings are not as indicated
in Table 1, do not proceed
with station start-up; contact
your local E/One distributor.
4. Turn “ON” the power to the
alarm panel from the building
service panel.
5. Using a test (volt) meter,
verify that the incoming panel
voltage is within 10% of the
pump nameplate voltage (for
240V pump, voltage at panel
must be 216V to 264V). If the
voltage is outside of this
range, do not continue with
station start-up. The voltage
problem must be corrected
prior to proceeding.
START-UP TEST
When the system is complete
and ready for use, the following
steps should be taken to
verify proper installation and
operation:
PIN
1
2
3
4
5
6
a) Make sure that the
discharge shutoff valve is fully
open. This valve must not
be closed when the pump is
operating. In some installations
there may be a valve, or
valves, at the street main that
must also be open.
b) Turn on the alarm power
circuit breaker. If a Protect
Plus panel is used, “Failed WM
Comm” will be indicated.
c) Fill tank with water until the
alarm turns on. Shut off water.
d) Turn ON pump power
circuit breaker; the pump
should turn on immediately.
Within one minute the alarm
will turn off. Within three
minutes the pump will turn off.
If a Protect panel is used, the
Trouble LED may come on. If
a Protect Plus panel is used,
Trouble/Brown Out may be
indicated.
e) If using a Protect panel,
turn the pump and alarm
breakers off and back on to
FUNCTION
2000S
EXTREME
MANUAL RUN
RED
BROWN
L1
BLACK
RED
L2
WHITE
BLACK
GND
GREEN GRN/YEL
ALARM FEED
ORANGE YELLOW
ALARM RETURN
BLUE
BLUE
30A BREAKER IS
REQUIRED
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clear and reset the panel. On
Protect Plus panels, perform a
“cold start” to clear and reset
the panel (any user setting that
were previously chosen will not
be reset).
OPERATIONAL ELECTRICAL
TEST
The following electrical test is
recommended in conjunction
with the Start-Up Test of the
grinder pump station. This test
requires the use of appropriate
electrical test equipment and
should only be performed by
qualified personnel trained
in the safe operation of this
equipment and electrical
system servicing.
Make sure that the discharge
shutoff valve is fully open. This
valve must not be closed when
the pump is operating. In some
installations there may be a
valve, or valves, at the street
main that must also be open.
(Ignore all Trouble
indications, LEDs and/or
messages until the panel
is reset at the end of this
procedure.)
1. The current to the grinder
pump should be measured in
the alarm panel, at the white
wire supplying the pump station
(supply cable).
2. Using an ammeter,
measure the current in the
white wire while the pump is
operating.
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3. The current should be
between 5 amps and 8 amps.
4. Higher amperage indicates
higher discharge pressure.
Measured current in excess
of 8 amps could indicate a
blocked or closed discharge
line. Correct any blockage
problems and confirm that the
current is within the acceptable
range. If the current remains
outside of the acceptable
range, and no discharge
blockage is detected, contact
your local Gatorgrinder
or qualified service
representative.
5. Clear/Reset the alarm
panel:
Sentry and T260 panels:
Reset is not required.
Protect Panel: Turn pump
and alarm breakers off and
back on simultaneously.
Protect Plus Panels: Perform
a “cold start” from the Initialize
System menu. Any user setting
that were previously chosen
will not be reset.
If the grinder pump fails to
perform as indicated, review
the start-up procedure again
and verify that all wiring
connections are correct
in accordance with these
instructions. If the grinder
pump still fails to perform as
indicated, contact your local E/One distributor.
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A Precision Castparts Company
Environment One Corporation
2773 Balltown Road
Niskayuna, New York 12309–1090
Voice: (01) 518.346.6161
Fax: 518.346.6188
www.eone.com
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NA0070P01 Rev D
2/17
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